Plastic window frame trim for corrugated building walls and installation method

ABSTRACT

A plastic window frame trim is for installation of a window in a corrugated metal building wall having a cut opening with a top edge, bottom edge, and side edges, each of the edges being backed by framing members. The window frame trim includes: a frame header J-channel with a flange; a frame footer J-channel with a flange; a pair of nailing fins; and fasteners. The trim header J-channel, footer J-channel, and nailing fins are attached to the window frame. The window frame is lifted so frame header J-channel flange slides between the top edge of the metal building wall and a framing member at the top of the cut opening. The window is lowered so footer J-channel flange slides between the bottom edge of the metal building wall and a framing member at the bottom of the cut opening so that window frame rest on the window sill. Fasteners attach the window frame to the framing members through the metal building wall. Trim caps snap over the nailing fins to finish the trimmed window.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation application of U.S. Utilitypatent application Ser. No. 13/166,374, filed Jun. 22, 2011, which is acontinuation-in-part of U.S. Utility patent application Ser. No.12/914,569 filed Oct. 28, 2010.

BACKGROUND OF THE INVENTION

The present invention relates to a vinyl or other plastic frame that canbe attached to a standard residential vinyl window to permit the windowto be inserted into the corrugated wall of a structure such as a steelclad post frame building, with a fully trimmed window frame that willaccommodate the raised ribs of the building skin.

Buildings constructed of corrugated steel sheet panels have been used inorder to reduce the cost of industrial-type or residential-typebuildings. A corrugated metal building can be constructed by formingcorrugated sheet into load carrying, spaced apart upright walls.

However, when it is necessary to form a window opening in the corrugatedwall of such a building, it would be advantageous to use pre-hung,standard residential windows of the horizontal slider, single hung,double hung, or other type. Such standard windows are typicallyinstalled in non-corrugated walls by framing an opening in the wall withwood or metal members, such as studs, headers and sill cross members andthen nailing or otherwise fastening the window to the framing studs.Because of the corrugated walls, a standard residential window will notfit flush with the exterior building wall and the corrugated walls donot permit the use of standard moldings. Therefore an external frame isdesirable to cover the rough-cut opening. Also, the metal wall willexpand and contract and the frame must permit this.

There is therefore a need for an easily-attachable frame for aresidential window that will permit the window to be installed in a cutopening in the corrugated building wall and cover the unsightlycomponents of the standard window frame. The frame must also tightlyseal the window against water penetration.

The frame must be paintable; must be fully trimmed; should dramaticallyreduce installation labor; be tolerant of thermal expansion andcontraction; and divert all water to the building exterior.

SUMMARY OF THE INVENTION

The present invention is a vinyl or other plastic frame trim for atypical residential vinyl window. In the preferred embodiment, theinvention consists of various PVC extrusions functioning as J-channelheader and sill, vertical nail fins, and vertical trim caps to adapt tothe accessory groove of a particular window master frame.

The vertical nailing fins and horizontal J-channels are snapped into theaccessory groove of the window master frame at the factory. Screws areapplied to secure the J-channels to the nailing fins at the factory, andthe window can be shipped with the vertical trim caps to be appliedlater. Alternatively, the J-channel and nailing fins can be applied tothe window conventionally with screws, glue or welding.

The window is installed with the back fin or vertical flange of theJ-channels just behind the building skin, and the nailing fins on theouter surface of the building skin, with screws through the nailing finsto secure the window to the structure. Trim caps are then applied overthe nailing fins to conceal all installation fasteners.

A principle object and advantage of the present invention is that it caneasily be attached to a standard window frame with or without anaccessory groove.

Another principle object and advantage of the present invention is thatit is easily adaptable to various window designs.

Another principle object and advantage of the present invention is thatit dramatically reduces installation labor and raw material costs.

Another object and advantage of the present invention is that it may beattached at the window factory or in the field.

Another object and advantage of the present invention is that ittolerates expansion and contraction of the corrugated metal buildingwall.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a vertical cross-section through a standard window W showingthe attachment of the upper and lower J-channels of the presentinvention.

FIG. 1A is a vertical cross-section through a standard window W showingconventionally attached upper and lower J-channels of the presentinvention.

FIG. 2 is a horizontal cross-section through the window of FIG. 1showing the attachment of the vertical nailing fins of the presentinvention.

FIG. 2A is a horizontal cross-section through the window of FIG. 1Ashowing conventionally attached vertical nailing fins of the presentinvention.

FIG. 3 is a front elevational view broken away of right vertical nailingfin.

FIG. 4 is a perspective view of a building wall section with windowopening exposed the window-building framework.

FIG. 5 is a vertical cross sectional view taken along lines 5-5 of FIG.4.

FIG. 6 is a horizontal cross sectional view taken along lines 6-7 ofFIG. 4.

FIG. 7 is a front elevational view of the building wall section withwindow opening exposed showing horizontal window cut extensions.

FIG. 8 is an enlarged view of one of the top horizontal window cutextensions of FIG. 7.

FIG. 9 is an enlarged view of one of the bottom horizontal window cutextensions of FIG. 7.

FIG. 10 is a vertical cross-sections through the window and exteriorplastic window trim showing installation of the window into the cut-outopening in the building wall.

FIG. 11 is a vertical cross-sections through the window opening showingthe window frame and exterior plastic window trim.

FIG. 12 is a vertical cross-sections through the window and exteriorplastic window trim showing installation of the window into the cut-outopening in the building wall.

FIG. 13 is a perspective view showing installation of the window withtrim into the cut-out opening in the building wall.

FIGS. 14 and 15 are similar to FIGS. 10 and 12 and show completion ofinstallation of the window into the cut-out opening in the buildingwall.

FIG. 16 is a perspective view showing the window with trim resting inthe cut-out opening in the building wall.

FIG. 17 is a partial perspective view of the window frame of the presentinvention showing fasteners being installed into the vertical nailingfins.

FIG. 18 is a perspective view of the window frame of the presentinvention after installation of the fasteners of FIG. 17.

FIG. 19 is a horizontal cross-section of the window frame of the presentinvention secured to the building wall by fasteners.

FIG. 20 shows the installation of the fasteners of FIG. 19.

FIGS. 21-22 are cross-sections of the building wall and window frame atapproximately the lines 21 and 22, respectively, of FIG. 16.

FIGS. 23-24 are perspective views of the vertical nailing fins andheader J-channels.

FIGS. 25-26 are cross-sections of the window frame of the presentinvention showing the installation of trim caps on the vertical nailingfins.

FIG. 27 is a perspective view of the window frame of the presentinvention after installation.

FIG. 28 is an enlarged view of the circled portion of FIG. 27 aftercomplete installation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A typical residential vinyl or wood window is shown in FIG. 1 asreference W. The window W has the following parts (as a typicalminimum): a frame F, into which is secured window glass sash G; and anoptional accessory groove AG around the perimeter of the frame F.Depending on the window type, other components such as sliders, screens,etc. may be present but are not required for the present invention.

The present invention (see FIGS. 1, 2 and 3) comprises a plastic oraluminum exterior window trim 10, which in turn comprises: a frameheader J-channel 20; a frame footer or sill J-channel 25; and verticalnailing fins 30. The frame J-channels 20, 25 have vertical flanges 21,26, attachment barbs 22, 27, gutter channels 23, 28 and lips 24, 29.

The vertical nailing fins 30 have attachment barbs 32, trim cap detents32, trim cap barbs or detents 33, trim cap outward extensions 34, screwchannels 35, screw apertures 36 which may be crisscross for expansionallowance.

The present invention in FIGS. 1A and 2A is an exterior window trim 10.5which fastens to window W without use of an accessory groove AG. Trim10.5 comprises a frame header J-channel 20.5, a frame footer or sillJ-channel 25.5 as vertical nailing fins 21.5, 26.5, attachment flanges22.5, 27.5, 31.5 instead of barbs 22, 27, 31, gutter channels 23.5, 28.5and lips 24.5, 29.5. Flanges 22.5 and 27.5 are screwed, glued and/orwelded to the top and bottom of frame F as shown. Flanges 31.5 aresimilarly screwed, glued and/or welded to the sides of frame F as shown.

At the building site, as shown in FIGS. 4-9, an opening 40, appropriateto the size of the window W, is then cut into the building skin B, andthe opening 40 is framed on the inside of the building with wood framingmembers including adjacent vertical wood or metal studs WS, sill crossmember S, and header cross member H. The horizontal window opening cutsin the window opening 40 are slightly extended 45 to receive extensionsof the J-channels 20 and 25 as to overhang window opening 40 to decreasethe chance of water entering the window opening 40 after completeinstallation which will be appreciated later.

Installation of the present invention into a residential window proceedsas follows.

First, the frame header J-channel 20 and frame footer J-channel 25 areattached to the accessory groove AG of the window W by pressing theattachment barbs 22, 27 into the accessory groove AG until they snapinto place, as shown in FIG. 1. Sealant 38 may be applied to theJ-channel along the attachment barbs 22, 27 adjacent the accessorygrooves AG before the J-channels 20 and 25 are thus attached.Alternatively, flanges 22.5 and 27.5 are conventionally secured towindow frame F.

Next, the vertical nailing fins 30 are attached to the accessory grooveAG by pressing the attachment barbs 32 into the accessory groove AGuntil they snap into place, as shown in FIG. 2. Sealant 33 may beapplied to the nailing fin attachment barbs 31 adjacent the accessorygroove AG before the vertical nailing fins 30 are thus attached. Again,alternatively, flanges 31.5 are conventionally secured to window frameF.

Screws 37 are driven through the ends of the J-channels 20 and 25 atdetents (not shown) into screw channels 35 formed in the extrudednailing fins 30.

As discussed, the above steps may be completed at the factory or in thefield.

Before installation, a bead of sealant 38 is laid down on the back sideof the nailing fins 30 as shown in FIG. 11. Next, shown in steps inFIGS. 10-15, the vertical flange 22 of the header J-channel 20 is slidup behind the building skin B so that the flange 22 is pressed betweenthe building skin B and the upper framing member or header cross memberH. This is done while the bottom of window frame F rests on the outsideof the building skin B and sill S.

Next, the window W with trim 10 is lifted upwardly and as shown in FIGS.12-14. The vertical flange 26 of the footer J-channel 25 is slid behindthe building skin B so that the flange 22 is pressed between thebuilding skin B and the lower framing member or sill cross member S. Thewindow is then lowered downwardly until the gutter channel 28 of thefooter J-channel 25 rests in contact with the building skin B and windowframe F rests upon the sill cross member S shown in FIGS. 15-19.

Next, as shown in FIG. 17, fasteners or screws 37 are driven throughscrew apertures 36 in the vertical nailing fins 30, though the buildingskin B, and into the vertical framing member or studs WS. Preferably,one or more of the apertures 36 may be slotted to allow for bothhorizontal and vertical expansion of the window frame W and it rest onthe sill cross member S.

FIGS. 19-20 shows screws or lag bolts 55 being driven through thebuilding skin B behind the header and footer J-channels 20, 25 and intothe horizontal header and sill framing members H, S. This will pinch thevertical flanges 21, 26 tightly into place in the window opening 40.

As shown in FIGS. 21 and 22, sealant 38 maybe applied along the exteriorvertical edges of nailing fins 30. FIGS. 23 and 24 show sealant 38 isthen applied at the horizontal ends of the frame header J-channel 20where the vertical nailing fins 30 abut against the building skin B,thus sealing the corrugated building skin B to the header J-channel 20at both ends and covering horizontal window cut extensions 45. A bead ofsealant 38 may also be laid down where vertical flange 21 under laps thebuilding skin B between J-channel 20 ends. Similarly, sealant is appliedat the horizontal ends of the footer J-channel 25 where the verticalnailing fins 30 abut against the building skin B, thus sealing thecorrugated building skin B to the sill or footer J-channel 25 at bothends and covering horizontal window cut extensions 45. A bead of sealant38 may also be laid down where vertical flange 26 under laps thebuilding skin B between footer J-channel 25 ends.

The final step in installation, as shown in FIGS. 25-27, is to attachthe vertical trim caps 60 to the vertical nailing fins 30, suitably bypress-fitting them against the exterior of the vertical nailing fins 30.For this purpose, the vertical trim caps 60 may have barbs 62 which willinterlock with trim cap detents 32 and trim cap barbs 33.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. Although methods and materialssimilar to or equivalent to those described herein can be used in thepractice or testing of the present invention, suitable methods andmaterials are described below. The present invention may be embodied inother specific forms without departing from the spirit or essentialattributes thereof, and it is therefore desired that the presentembodiment be considered in all respects as illustrative and notrestrictive, reference being made to the appended claims rather than tothe foregoing description to indicate the scope of the invention.

What is claimed:
 1. A window frame exterior trim separate from and for awindow with a frame having a top, bottom and sides, the window frame tobe mounted in a corrugated metal building wall having a corrugatedexterior skin, a vertically dimensioned cut window opening with internaladjacent vertical window studs and internal adjacent horizontal headerand sill cross members, the window frame trim comprising: (a) anupwardly directed exposed header J-channel separate from the windowframe having a rearwardly directed attachment flange securable to thetop of the window frame, an upwardly directed exposed water deflectinggutter channel and a vertical flange to be positioned between thebuilding skin and header cross member; (b) a downwardly directed exposedfooter J-channel separate from the window frame having a rearwardlydirected attachment flange securable to the bottom of the window frame,a vertical flange to be positioned between the building skin and footercross member; (c) a pair of vertical fins separate from the window frameeach having a rearwardly directed attachment flange securable to one ofthe window frame sides; and (d) vertical fin trim caps to be fastenedover and on top of the vertical fins.
 2. The window frame trim of claim1, wherein the fins each further comprise a trim cap outward extensiongenerally 90° from the window.
 3. The window frame trim of claim 2,wherein the fins and trim cap outward extensions have vertical screwchannels for receiving screws through the J-channels to secure theJ-channels to the fins.
 4. A window frame exterior trim separate fromand for a window with a frame having top, bottom and sides, the windowframe to be mounted in a corrugated metal building wall having acorrugated exterior skin, a vertically dimensioned cut window openingwith internal adjacent vertical window studs and internal adjacenthorizontal header and sill cross members, the window frame trimcomprising: (a) an upwardly directed exposed header J-channel separatefrom the window frame having a rearwardly directed attachment flangesecurable to the top of the window frame, an upwardly directed exposedwater deflecting gutter channel and a vertical flange to be positionedbetween the building skin and header cross member; (b) a downwardlydirected exposed footer J-channel separate from the window frame havinga rearwardly directed attachment flange securable to the bottom of thewindow frame, a vertical flange to be positioned between the buildingskin and footer cross member; (c) a pair of vertical fins separate fromthe window frame each having a rearwardly directed attachment flangesecurable to one of the window frame sides wherein the fins each furthercomprise a trim cap outward extension generally 90° from the window; and(d) vertical fin trim caps to be fastened over and on top of thevertical fins, wherein the window frame trim is dimensioned verticallygreater than the vertically dimensioned cut window opening to secure thewindow trim behind the building skin.
 5. The window frame trim of claim4, wherein the fins and trim cap outward extensions have vertical screwchannels for receiving screws through the J-channels to secure theJ-channels to the fins.
 6. A window frame exterior trim for a windowwith a top, bottom and sides with accessory grooves therearound, thewindow to be mounted in a corrugated metal building wall having acorrugated exterior skin, a vertically dimensioned cut window openingwith internal adjacent vertical window studs and internal adjacenthorizontal header and sill cross members, the window frame trimcomprising: (a) an upwardly directed exposed and open header J-channelhaving a rearwardly directed attachment flange with a rearwardlydirected barb securable to the top accessory groove of the window, anupwardly directed exposed and open water deflecting gutter channel and avertical flange adapted to be positioned between the building skin andheader cross member; (b) a downwardly directed exposed and open footerJ-channel having a rearwardly directed attachment flange with arearwardly directed barb securable to the bottom accessory groove of thewindow, a vertical flange adapted to be positioned between the buildingskin and footer cross member; (c) a pair of vertical fins each having arearwardly directed attachment flange with a rearwardly directed barbsecurable to one of the window sides accessory grooves; and (d) verticalfin trim caps to be fastened over and on top of the vertical fins. 7.The window frame trim of claim 6, wherein the fins each further comprisea trim cap outward extension generally 90° from the window.
 8. Thewindow frame trim of claim 7, wherein the fins and trim cap outwardextensions have vertical screw channels for receiving screws through theJ-channels to secure the J-channels to the fins.
 9. A window frameexterior trim for a window with a top, bottom and sides with accessorygrooves therearound, the window to be mounted in a corrugated metalbuilding wall having a corrugated exterior skin, a verticallydimensioned cut window opening with internal adjacent vertical windowstuds and internal adjacent horizontal header and sill cross members,the window frame trim comprising: (a) an upwardly directed exposed andopen header J-channel having a rearwardly directed attachment flangewith a rearwardly directed barb securable to the top accessory groove ofthe window, an upwardly directed exposed and open water deflectinggutter channel and a vertical flange adapted to be positioned betweenthe building skin and header cross member; (b) a downwardly directedexposed and open footer J-channel having a rearwardly directedattachment flange with a rearwardly directed barb securable to thebottom accessory groove of the window, a vertical flange adapted to bepositioned between the building skin and footer cross member; (c) a pairof vertical fins each having a rearwardly directed attachment flangewith a rearwardly directed barb securable to one of the accessorygrooves of the window sides wherein the fins each further comprise atrim cap outward extension generally 90° from the window; and (d)vertical fin trim caps to be fastened over and on top of the verticalfins, wherein the window frame trim is dimensioned vertically greaterthan the vertically dimensioned cut window opening to secure the windowtrim behind the building skin.
 10. The window frame trim of claim 9,wherein the fins and trim cap outward extensions have vertical screwchannels for receiving screws through the J-channels to secure theJ-channels to the fins.
 11. A method of installing a plastic extrudedwindow frame exterior trim separate from but mounted onto a window framehaving a top, a bottom and sides, the window frame to be installed in acorrugated metal building wall having a corrugated exterior skin, avertically dimensioned cut window opening smaller than a verticaldimension of the window frame exterior trim, the window opening havinginternal adjacent vertical window studs and internal adjacent horizontalheader and sill cross members, the method comprising: (a) lifting thewindow frame with the exterior trim fastened therearound having anupwardly directed exposed header J-channel having a rearwardly directedattachment flange secured to the top of the window frame and an upwardlydirected vertical flange to be positioned between the building skin andheader cross member; (b) lowering the window frame with the exteriortrim fastened therearound having a downwardly directed exposed footerJ-channel having a rearwardly directed attachment flange secured to thebottom of the window frame and a vertical flange to be positionedbetween the building skin and footer cross member thereby resting thewindow on the sill cross member; (c) resting a pair of trim verticalfins of the exterior trim each having a rearwardly directed attachmentflange secured to one of the window frame sides against the corrugatewall adjacent the window studs; (d) securing with fasteners the verticalflanges behind the building skin; and (e) fastening vertical fin trimcaps over the vertical fins.